U.S. patent number 7,473,864 [Application Number 10/848,165] was granted by the patent office on 2009-01-06 for weldment of different materials and resistance spot welding method.
This patent grant is currently assigned to Kobe Steel, Ltd., Nisshin Steel Co., Ltd.. Invention is credited to Shunichi Hashimoto, Mitsuo Hino, Tetsu Iwase, Jun Katoh, Seiji Sasabe, Fumihiro Sato, Hiroyuki Takeda, Kensuke Tsubota.
United States Patent |
7,473,864 |
Iwase , et al. |
January 6, 2009 |
Weldment of different materials and resistance spot welding
method
Abstract
A joined part of an aluminum-coated steel sheet and an aluminum
sheet is composed of an intermetallic compound layer which exists
in a region in which a part of a coated layer exists before the
joining and an aluminum melted and solidified part which also
exists on the side of the aluminum sheet to enclose the
intermetallic compound layer. The atoms existing on the surface of
the aluminum melted and solidified part are intermetallic-bonded
with atoms which exist on the surface of the steel sheet except in
the region in which the intermetallic compound layer exists seen in
the plan view. Further, the area of the intermetallic compound
layer is limited to 60% or less of the total area of the joined
part at the interface between the aluminum-coated steel sheet and
the aluminum sheet. Thus, the area of the aluminum melted and
solidified part exceeds 40% of the total area of the joined part.
The strong joining having a high fracture energy can be provided at
a high efficiency.
Inventors: |
Iwase; Tetsu (Fujisawa,
JP), Sasabe; Seiji (Fujisawa, JP), Hino;
Mitsuo (Tokyo, JP), Tsubota; Kensuke (Tokyo,
JP), Sato; Fumihiro (Moka, JP), Hashimoto;
Shunichi (Kakogawa, JP), Katoh; Jun (Kobe,
JP), Takeda; Hiroyuki (Kobe, JP) |
Assignee: |
Kobe Steel, Ltd. (Kobe-shi,
JP)
Nisshin Steel Co., Ltd. (Tokyo, JP)
|
Family
ID: |
35374193 |
Appl.
No.: |
10/848,165 |
Filed: |
May 19, 2004 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20050258145 A1 |
Nov 24, 2005 |
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Current U.S.
Class: |
219/118;
428/653 |
Current CPC
Class: |
B23K
11/20 (20130101); B23K 11/34 (20130101); Y10T
428/12757 (20150115) |
Current International
Class: |
B23K
11/16 (20060101) |
Field of
Search: |
;219/118,117.1,119,76.17,85.16,86.1,86.25,91.2 ;427/318,319
;428/653,570,659 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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04-251676 |
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Aug 1992 |
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JP |
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4-251676 |
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Sep 1992 |
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JP |
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04-251676 |
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Sep 1992 |
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JP |
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4-253578 |
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Sep 1992 |
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JP |
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7-24581 |
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Jan 1995 |
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JP |
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07-024581 |
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Jan 1995 |
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JP |
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9-176816 |
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Jul 1997 |
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JP |
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11-342477 |
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Dec 1999 |
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JP |
|
Primary Examiner: Kerns; Kevin P
Assistant Examiner: Aboagye; Michael
Attorney, Agent or Firm: Oblon, Spivak, McClelland, Maier
& Neustadt, P.C.
Claims
What is claimed is:
1. A weldment of different materials, the weldment having a ductile
fracture energy of at least 7.5 Joules, comprising: an aluminum or
aluminum alloy sheet and an aluminum-coated steel sheet having an
aluminum coated layer with a thickness of 15 .mu.m or more, said
aluminum or aluminum alloy sheet and said aluminum-coated steel
sheet being resistance spot welded, wherein a joined part exists on
an interface between the aluminum or aluminum alloy sheet and the
aluminum-coated steel sheet, and wherein the area of an
intermetallic compound layer in the joined part is 60% or less of
the total area of the joined part constituting the intermetallic
compound layer and the melted and solidified region created by the
resistance spot welding, wherein the aluminum-coated steel sheet
comprises a steel substrate containing 0.002% by mass or more of
N.
2. A weldment of different materials according to claim 1, wherein
the aluminum-coated steel sheet comprises an aluminum-coated layer
containing 5% by mass or more of Si.
3. A method of resistance spot welding the weldment of different
materials comprising an aluminum or aluminum alloy sheet and an
aluminum-coated steel sheet according to claim 1, comprising the
steps of pressing the aluminum-coated steel sheet against an
electrode chip at an anode, and pressing the aluminum or aluminum
alloy sheet against an electrode chip at a cathode side using a DC
or capacitor type welding machine.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a weldment of different materials
comprising an aluminum or aluminum alloy (hereinafter both of which
are referred to as "aluminum") sheet and an aluminum-coated steel
sheet, and a method of resistance spot welding the weldment.
2. Description of the Related Art
Aluminum is widely used for vehicles and automobiles as
light-weight structural materials. Due to various factors including
costs, strength and stiffness, aluminum is often used in
combination with a steel sheet. The steel sheet is typically joined
to each other using resistance spot welding in a simply way. Also,
it is required to resistance spot weld aluminum with a steel sheet
to provide a joined material.
It is conventionally known that when an aluminum sheet and a steel
sheet are directly resistance spot welded, a hard and brittle
intermetallic compound is produced at an interface between the
aluminum sheet and the steel sheet, resulting in a joined material
having a significantly decreased strength.
In order to provide sufficient strength, a coating layer is formed
on a steel sheet as disclosed, for example, in Japanese Unexamined
Patent Application Publication No. 4-251676.
Also, an insert material is interposed between an aluminum sheet
and a steel sheet, and they are resistance spot welded as disclosed
in, for example, Japanese Unexamined Patent Application Publication
No. 4-253578.
However, the strength is not sufficient after joining, although the
coating layer is formed on the steel sheet. In addition, even if
the strength is sufficient, the fracture energy is low, whereby no
joined material suitable for use in structures such as vehicles and
automobiles can be provided.
The resistance spot welding using the insert material is
insufficient and not suitable for a large number of joinings.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a
weldment of different materials and a method of resistance spot
welding in which a strong joining having a high fracture energy is
provided at a high efficiency.
One aspect of the present invention provides a weldment of
different materials comprising an aluminum or aluminum alloy sheet
and an aluminum-coated steel sheet that are resistance spot welded,
wherein a joined part exists on an interface between the aluminum
or aluminum alloy sheet and the aluminum-coated steel sheet, and
wherein the area of an intermetallic compound layer in the joined
part is 60% or less of the total area of the joined part
constituting of the intermetallic compound layer and the melted and
solidified region by the resistance spot welding.
In the weldment of different materials according to the present
invention, the aluminum-coated steel sheet comprises a steel
substrate containing 0.002% by mass or more of N.
In addition, in the weldment of different materials according to
the present invention, the aluminum-coated steel sheet comprises an
aluminum-coated layer containing 5% by mass or more of Si.
Furthermore, in the weldment of different materials according to
the present invention, the aluminum-coated steel sheet comprises an
aluminum-coated layer having a thickness of 15 .mu.m or more.
Another aspect of the present invention provides a method of
resistance spot welding a weldment of different materials
comprising an aluminum or aluminum alloy sheet and an
aluminum-coated steel sheet according to the present invention
comprising the steps of pressing the aluminum-coated steel sheet
against an electrode chip at an anode, and pressing the aluminum or
aluminum alloy sheet against an electrode chip at a cathode side
using a DC or capacitor type welding machine.
According to the present invention, the area of the intermetallic
compound layer formed at the interface is adequately defined based
on the total area of the weldment, thereby providing the strong
weldment having a high ductile fracture energy.
The above-mentioned aluminum-coated steel sheet comprises a steel
substrate and an aluminum-coated layer or an aluminum alloy coated
layer formed thereon.
When a DC or capacitor type welding machine is used, the
aluminum-coated steel sheet is pressed against an electrode chip at
an anode, and the aluminum or aluminum alloy sheet is pressed
against an electrode chip at a cathode side, thereby ensuring an
area percentage.
It is preferable that the aluminum-coated steel sheet comprises an
aluminum-coated layer containing 5% by mass or more of Si, the
aluminum-coated steel sheet comprises an aluminum-coated layer
having a thickness of 15 .mu.m or more, and the aluminum-coated
steel sheet comprises a steel substrate containing 0.002% by mass
or more of N.
As described above, according to the present invention, the area of
the intermetallic compound layer formed at the interface between
the aluminum or aluminum alloy sheet and the aluminum-coated steel
sheet is adequately defined based on the total area of the
weldment, thereby providing the strong weldment having a high
ductile fracture energy.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a weldment of different
materials according to an embodiment of the present invention;
FIG. 2 is a schematic view showing a joined part 3 at the interface
between an aluminum-coated steel sheet 1 and an aluminum sheet
2,
FIG. 3A shows a current waveform in a single-phase AC type welding
machine,
FIG. 3B shows a current waveform on welding points in odd numbers
in a three-phase low frequency type welding machine,
FIG. 3C shows a current waveform in an inverter (AC) type welding
machine,
FIG. 4A shows a current waveform in a single-phase rectifier type
welding machine,
FIG. 4B shows a current waveform in a three-phase rectifier type
welding machine,
FIG. 4C shows a current waveform in an inverter (DC) type welding
machine,
FIG. 5 shows a current waveform in a capacitor type welding
machine, and
FIG. 6 is a graph showing a load--displacement curve where the
displacement is on the abccissa and the load is on the ordinate in
Example 1 and Comparative Example 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the attached drawings, preferable embodiments of the
weldment of different materials according to the present invention
will be described in detail. FIG. 1 is a sectional view showing a
weldment of different materials according to an embodiment of the
present invention. FIG. 2 is a schematic view showing a joined part
3 at the interface between an aluminum-coated steel sheet 1 and an
aluminum sheet 2.
In this embodiment, the aluminum-coated steel sheet 1 is joined on
the aluminum sheet 2 by resistance spot welding. Aluminum-coated
layers 1b and 1c are formed on both surfaces of a steel substrate
1a of the aluminum-coated steel sheet 1. Intermetallic compound
layers consisted of an Al--Fe composition and the like (not shown)
exist on interfaces between the coated layer 1b and the steel sheet
1a, and between the coated layer 1c and the steel sheet layer 1a
before the aluminum-coated steel sheet 1 is joined with the
aluminum sheet 2.
A joined part 3 of the aluminum-coated steel sheet 1 and the
aluminum sheet 2 includes an intermetallic compound layer 3a and an
aluminum melted and solidified part 3b. The intermetallic compound
layer 3a is formed on a part of the coated layer 1b before joining.
The aluminum melted and solidified part 3b is formed within the
aluminum sheet 2, and surrounds the intermetallic compound layer
3a. The atoms existing on the surface of the aluminum melted and
solidified part 3b are metallic-bonded with atoms which exist on
the surface of the steel sheet 1 except in the region in which the
intermetallic compound layer 3a exists seen in the plan view. In
other words, the intermetallic compound consisted of the Al--Fe
composition and the like that exists before the joining disappears
in the region where the aluminum melted and solidified part 3b and
the steel sheet 1 are directly contacted. The intermetallic
compound layer 3a is the intermetallic compound that exists before
the joining or is newly developed upon the joining.
In this embodiment, the area of the intermetallic compound layer 3a
at the interface between the aluminum-coated steel sheet 1 and the
aluminum sheet 2 is limited to 60% or less of the total area of the
joined part 3 constituting of the intermetallic compound layer 3a
and the aluminum melted and solidified part 3b. Accordingly, the
area of the aluminum melted and solidified part 3b exceeds 40% of
the total area of the joined part 3.
According to this embodiment, the aluminum sheet 2 and the steel
sheet 1 are intermetallic bonded over a wide area, resulting in a
strong joining having a high fracture energy, even if no insert
material is used.
A method of resistance spot welding the weldment of different
materials described above will be described. The present inventor
found that positive charges flow into the joining material from an
electrode chip to produce deviations of the heat generations on the
joining material in the resistance spot welding, and that when the
deviations of the heat generations on the aluminum sheet 2 is
produced at one welding point, the aluminum sheet 2 is molten
intensively to produce a large amount of the intermetallic
compound, whereby the percentage of the area of the intermetallic
compound layer 3a that occupies the joining part 3 is increased. It
is therefore required to avoid excessive heating of the aluminum
sheet 2. In the resistance spot welding method, any of an AC, DC or
capacitor type welding machine can be used.
A method of resistance spot welding using the AC type welding
machine will be described. FIG. 3A shows a current waveform in a
single-phase AC type welding machine. FIG. 3B shows a current
waveform on welding points in odd numbers in a three-phase low
frequency type welding machine. FIG. 3C shows a current waveform in
an inverter (AC) type welding machine.
In the single-phase AC or the inverter type welding machine, a
positive current flows alternatively through a positive electrode
chip and a negative electrode chip, as shown in FIGS. 3A and 3C.
Accordingly, the electrode chips having either polarity can be
pressed against the aluminum-coated steel sheet 1 and the aluminum
sheet 2, since no deviations of the heat generations are
produced.
In the three-phase low frequency type welding machine, a positive
current flows at a positive electrode on welding points in odd
numbers as shown in FIG. 3b, and a positive current flows at a
negative electrode on welding points in even numbers (not shown).
If the negative electrode chip is pressed against the
aluminum-coated steel sheet 1 on the welding points in odd numbers
and the positive electrode chip is pressed against the aluminum
sheet 2 using the three-phase low frequency type welding machine,
the deviations of the heat generations are produced on the aluminum
sheet 2, as described above. As a result, no desired weldment can
be provided. The same applies to the case that the positive
electrode chip is pressed against the aluminum-coated steel sheet 1
on the welding points in even numbers and the negative electrode
chip is pressed against the aluminum sheet 2. Accordingly, the
polarity of the electrode chip should be changed per one welding
point, when the three-phase low frequency type welding machine is
used.
A method of resistance spot welding using the DC type welding
machine will be described. FIG. 4A shows a current waveform in a
single-phase rectifier type welding machine. FIG. 4B shows a
current waveform in a three-phase rectifier type welding machine.
FIG. 4C shows a current waveform in an inverter (DC) type welding
machine.
In the single-phase rectifier, three-phase rectifier, or the
inverter type welding machine using the DC current, the positive
current flows only on the positive electrode chip as shown in FIGS.
4A to 4C. Accordingly, it is required to press the positive
electrode chip to the aluminum-coated steel sheet 1 and to press
the negative electrode chip to the aluminum sheet 2.
A method of resistance spot welding using the capacitor type
welding machine will be described. FIG. 5 shows a current waveform
in a capacitor type welding machine. In the capacitor type welding
machine, the positive charges stored on the capacitor flow to the
positive electrode chip at an initial pulse, and then attenuate.
Accordingly, when the positive electrode chip is pressed to the
aluminum-coated steel sheet 1 and the negative electrode chip is
pressed to the aluminum sheet 2, the deviations of the heat
generations is produced on the aluminum-coated steel sheet 1,
whereby the production of a large amount of the intermetallic
compound can be avoided.
The causes of the numerical limitations to the shape and the
composition of the joined material will be described.
According to the present invention, the aluminum-coated layer
contains 5% by mass or more of Si. If the aluminum-coated layer
contains less than 5% by mass of Si, the amount of the
intermetallic compound may be increased in the joined part.
Although the composition of the aluminum-coated layer is not
especially limited, the aluminum-coated layer desirably contains 5%
by mass or more of Si.
According to the present invention, the aluminum-coated layer has a
thickness of 15 .mu.m or more. If the aluminum-coated layer has a
thickness of less than 15 .mu.m, the amount of the intermetallic
compound may be increased in the joined part. Although the
thickness of the aluminum-coated layer is not especially limited,
the aluminum-coated layer desirably has a thickness of 15 .mu.m or
more.
According to the present invention, the aluminum-coated steel sheet
comprises a steel substrate containing 0.0020 to 0.0200% by mass of
N. If the steel substrate contains less than 0.0020% by mass of N,
the amount of the intermetallic compound may be increased in the
joined part. If the steel substrate contains more than 0.0200% by
mass of N, the strength in the joining is not improved. Although
the composition of the aluminum-coated layer is not especially
limited, the aluminum-coated steel sheet desirably comprises a
steel substrate containing 0.0020 to 0.0200% by mass or more of
N.
Non-limiting examples of the aluminum material include 1000, 3000,
or 5000 series aluminum or aluminum alloy.
As defined in the present invention, in order to limit the area of
the intermetallic compound layer to 60% or less of the total area
of the joined part at the interface between the aluminum-coated
steel sheet and the aluminum sheet, it is thus required to
adequately select the resistance spot welding method and the shape
and the composition of the joined material. As to the composition
of the joined material, the aluminum-coated steel sheet comprises a
steel substrate containing as high as 0.002% by mass or more of
N.
Examples of the weldment of different materials according to the
present invention and comparative examples will be described
below.
Joined bodies of different materials having various area
percentages were produced by joining aluminum-coated steel sheets
with JIS5056A1 alloy plates shown in Table 1 under controlled
welding current and time conditions using a resistance spot welding
method. The area percentage herein refers to the percentage of the
area of the intermetallic compound layer to the area of the joined
part. Each of the aluminum-coated steel sheet and the Al alloy
plate had a thickness of 1.0 mm.
TABLE-US-00001 TABLE 1 Aluminum-coated Steel Sheet Al Coated Layer
N Content in Polarity at Area Si Content Thickness Steel Substrate
Welding Steel Sheet Percentage No (% by mass) (.mu.m) (% by mass)
Machine Side (%) Example 1 10 40 0.012 DC + 20 2 10 40 0.012 DC +
35 3 10 40 0.012 DC + 45 4 10 40 0.012 DC + 60 5 13 40 0.012 DC +
24 6 10 40 0.012 DC + 24 7 7 40 0.012 DC + 50 8 4 40 0.012 DC + 60
9 12 40 0.012 DC + 28 10 10 32 0.012 DC + 35 11 9 25 0.012 AC None
47 12 9 15 0.012 DC + 55 13 9 13 0.012 DC + 58 14 10 40 0.012 DC +
59 15 10 40 0.001 DC + 59 Comparative 16 10 40 0.012 DC + 70
Example 17 10 40 0.012 DC + 65 18 10 40 0.012 DC + 75
Respective joined bodies were tested for shear tension. Based on
the resultant load--displacement curve, ductile fracture energy was
determined by the energy required for fracture each weldment. The
results are shown in Table 2. In Table 2, the ductile fracture
energy of 8 J or more is excellent, 7.7 J or more but less than 8 J
is good, 7.5 J or more but less than 7.7 J is fair, and less than
7.5 J is not good. FIG. 6 is a graph showing a load--displacement
curve where the displacement is on the abccissa and the load is on
the ordinate in Example 1 and Comparative Example 18. In FIG. 6,
the solid line represents the result in Example 1, and the broken
line represents the results in Comparative Example 18.
TABLE-US-00002 TABLE 2 Ductile Fracture No. Broken Part Energy
Example 1 Base Material Excellent Broken 2 Base Material Excellent
Broken 3 Base Material Good Broken 4 Base Material Fair Broken 5
Base Material Excellent Broken 6 Base Material Excellent Broken 7
Base Material Good Broken 8 Base Material Fair Broken 9 Base
Material Excellent Broken 10 Base Material Good Broken 11 Base
Material Good Broken 12 Base Material Good Broken 13 Base Material
Fair Broken 14 Base Material Good Broken 15 Base Material Fair
Broken Comparative 16 Base Material Not Good Example Broken 17
Interface Broken Not Good 18 Interface Broken Not Good
As shown in Table 2, in Examples 1 to 15, the weldments had the
area percentages of 60% or less, had high ductile fracture energy
as high as 7.5 J or more, and had broken base materials. The
weldment in Example 8 had lower ductile fracture energy, since the
aluminum-coated layer contained less than 5% by mass of Si. The
weldment in Example 13 had lower ductile fracture energy, since the
aluminum-coated layer had a thickness of less than 15 .mu.m. The
weldment in Example 15 had lower ductile fracture energy, since the
steel substrate contained less than 0.002% by mass of N.
In contrast, in Comparative Examples 16 to 18, the joined bodies
had the area percentages exceeding the upper limit defined by the
present invention and therefore had low ductile fracture energy. In
particular, in Comparative Examples 17 and 18, the joined bodies
had broken interfaces.
Differences in the ductile fracture energy between the joined
bodies in Examples and Comparative Examples are represented by a
hatching region in FIG. 6.
* * * * *